Shoe with insole as part sole filler and method of making same

ABSTRACT

A method of manufacture of footwear and the footwear comprising the steps of providing a last with an upper thereon, providing a mold insert on the bottom of the last, providing a mold having a mold cavity for a tread sole, disposing the last and upper against the mold with the mold insert disposed within the mold cavity, forming a sole in the mold cavity having a depression therein in the shape of the mold insert, providing an insole with a first portion in the shape of the depression and a second portion substantially in the shape of the sole and securing the first portion of the insole in the depression. The tread sole and insole are formed of materials preferably having different physical properties. The tread sole can include one of tongues and grooves and the insole would then have the other of tongues and grooves, said tongues and grooves mating with each other. The step of providing an insole can include removing the mold insert from the mold cavity, disposing the last spaced from the tread sole and then forming the insole in the cavity formed by the removal of the weight relief and the spacing of the last from the tread sole.

This application is a Continuation, of application Ser. No. 08/101,964,filed Jun. 7, 1993 abandoned which is a continuation of Ser. No.07/650,783, filed Feb. 5, 1991, now abandoned.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to a shoe having a sole filler provided in partby an insole and a method of making the shoe.

2. Brief Description of the Prior Art

In the manufacture of footwear, it is known to mold soles of rubber,polyvinyl chloride (PVC), polyurethane or other elastomers eitherdirectly to the shoe upper or to a welt which has been stitched to theshoe upper. Typical examples of such prior art are set forth in thepatents of Auberry et al. U.S. Pat. No. 3,965,517 and 3,758,903. Whilefootwear of the type set forth in the above mentioned prior art operatesin satisfactory manner for the purposes intended, when a rigid sole isrequired, the sole tends to be heavy, relatively hard and does notprovide good thermal insulation. On the other hand, when rigidity is notrequired and properties other than those inherent in rigid soles aredesired, foamed soles have been utilized. British Patent No. 1,444,091discloses a shoe having a sole with cavities at the heel and ballregions with insertion of a resilient cushioning material therein at theball region only. This patent requires multiple inserts which areseparately insertable and discontinuous, thereby requiring added laborcost and failing to provide maximum thermal insulation. However, theprior art has not provided the combination of sole rigidity with solesoftness or cushioning, light weight and good thermal insulationproperties all in a single shoe.

SUMMARY OF THE INVENTION

In accordance with the present invention, there is provided a sole andmethod of making same which can provide the rigidity of the prior artrigid soles and still provide the other above noted desirable propertiesnot inherent in rigid soles.

Briefly, in accordance with the present invention, there is provided ashoe having an upper and a sole secured to the upper, either directly orthrough a welt the sole, is preferably rigid, and can have any desiredproperties, includes a hollow sole interior section extending from thetoe region to and under the ball and entire heel region into which issecured a preferably premolded insole of a material having the desiredproperties, preferably a relatively soft foam which provides cushioning,light weight and thermal insulation. The insole includes a cradled lipextending over the remaining interior portion of the sole which providesadded comfort and thermal insulation. The insole can be cradled asopposed to being flat to better conform to the contour of the wearer'sfoot. The insole is secured to the sole by means of adhesive, such as anepoxy, or by mating members in the sole and insole, such as a tongue andgroove, the tongue preferably being a portion of the insole and thegroove being premolded into the sole. The tongue and groove insoleembodiment can be made easily removable for the purpose of, for example,drying, airing or cleaning thereof.

The shoe with sole in accordance with the present invention isfabricated by placing an upper on a last in standard manner, placing amold insert in the shape of the hollow sole interior section on the lastbottom, the mold insert preferably being a permanent part of the lastbottom, bringing the sole plate or mold for the sole and the last withupper thereon together in standard manner and then forming the sole inthe sole plate. The sole will adhere to the welt or the upper as in theprior art. However, there will be a cavity in the sole in the shape ofmold insert, this cavity being the hollow sole interior section. Thesole will also contain grooves in the event the insole is to be matedtherewith.

An insole is preferably premolded and is preferably of a materialdifferent from that of the sole. This insole has a bottom portion whichis the same shape as the hollow sole interior section and fits therein,the remaining portion of the insole, or lip, lying above the sole andresting thereover. After removal of the upper from the last with moldinsert, the insole is secured to the sole either by an adhesive,preferably an epoxy, or by tongues formed in the bottom portion thereofwhich mate with the grooves in the sole, thereby providing a removableinsole. Of course, the tongues and grooves can be reversed.

As an alternative, the mold insert can be removed from the last afterformation of the sole and a second material can be inserted into thehollow sole interior section. In this case, the last without the moldinsert and the sole form the mold cavity for the second material.

The sole is formed from any of the known prior art moldable solematerials, all of which are well known. Preferable sole materials arethermoplastic materials, preferably PVC, and rubber. Preferable insolematerials are foams, preferably polyurethane and other blown materials.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of a molding last with mold insert in accordancewith the present invention;

FIG. 1A is a rear view of the molding last shown in FIG. 1, and

FIG. 1B is a bottom view of the molding last shown in FIG. 1.

FIG. 2 is a side view, partially in elevation and partially in section,of a molding last with upper in position for having a sole directlymolded to the upper in accordance with the present invention;

FIG. 3 is a side elevational view of a shoe after removal from themolding last with a cavity in the tread or outer sole within the shoe;

FIG. 4 is a view of a molded insole for use in accordance with e presentinvention;

FIG. 4A is a rear view of the molded insole shown in FIG. 4; and

FIG. 4B is a bottom view of the molded insole shown in FIG. 4.

FIG. 4c is a rear view of the molded insole of FIG. 4a; and

FIG. 5 is a side elevational view of a shoe in accordance with thepresent invention with insole/sole filler disposed in and over the treadsole.

FIG. 6 is a rear view of the molded insole and a partial rear view ofthe tread sole in a embodiment of the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring first to FIG. 1, there is shown a standard molding last 1having a mold insert 3 secured thereto. The mold insert 3 is shaped toprovide the hollow tread sole interior section to be discussedhereinbelow. A shoe upper 5, with or without a welt secured thereto, isdisposed over the molding last 1 with mold insert 3, as shown in FIG. 2,and the last is mechanically held in place against the sole frame 9,within which the sole plate 7 is moved upwardly to its proper positionwith the upper 5 or welt (not shown) in contact with the upper edge ofthe sole frame. The material from which the tread sole 11 is formed isthen entered into the hollow cavity of the sole plate between the soleplate and the mold insert 3 to form the tread sole 11. Everythingdiscussed to this point is done in standard manner with the exception ofthe use of the mold insert 3.

The upper 5 is then removed from the molding last 1 and mold insert 3.At his time, the tread sole 11 is secured to the upper 5, eitherdirectly or via a welt, and the cavity 13 wherein the mold insert 3 wasdisposed during molding of the tread sole is now hollow, this cavitybeing the hollow sole interior section and shown in FIG. 3. Groovesand/or tongues are optionally disposed in the tread sole 11 if the moldinsert 3 contains finger or groove portions to accommodate formationthereof during the tread sole molding step as shown in FIG. 6.

An insole 15 is then disposed in the hollow sole interior section asshown in FIG. 4. In accordance with one embodiment of the invention, asshown in FIGS. 4a to 4 c, the insole 15 is separately molded andincludes a lower portion 17 which has substantially the same shape asthe cavity 13 and an upper portion or lip 19 which preferably rests overthe entire upper surface of the tread sole 11 external of the carty. Theinsole 15 is secured to the tread sole 11 by an adhesive, preferably anepoxy, and/or by mating of tongue and groove members, if present, orjust inserted.

In accordance with another embodiment of the invention, after removal ofthe upper from the molding last 1 and mold insert 3, the mold insert isremoved from the molding last and the molding last is replaced in theupper at its original position therein except for some displacement fromthe tread sole 11 to permit a section similar to the upper portion 19 tobe formed. It is apparent that the space previously occupied by the moldinsert 3 is now a new cavity as well as the space between the tread sole11 and the molding last 1. Accordingly, in a second molding operation, asecond material, preferably a foam such as polyurethane, is inserted inthe newly formed cavity, the foam adhering to the tread sole 11 withinthe cavity 13 and also being disposed over the entire sole tread.

The end result of either of the above described procedures is a shoehaving an upper 5, a tread sole 11 and a separate insole 15 secured tothe tread sole and extending thereover as shown in FIG. 5. The insole 15can be permanently affixed to the tread sole 11, such as with an epoxy,or can be removable therefrom, such as with the use of the tongue andgroove members, as discussed hereinabove or just inserted. An example ofa tongue and groove arrangement is shown in FIGS. 6a and 6 b wherein theheel portion 21′ of the insole 15′ in FIG. 6a contains a groove 23extending therethrough and the tread sole 11′ includes a tongue 25having an outer contour the same as the inner contour of the groove 23,this being one example of many well known tongue and groovearrangements.

FIG. 6 shows a tongue and groove configuration wherein the tongue 31 isshown extending from the tread sole 11 and the groove 33 is shown formedin the insole 15.

Though the invention has been described with respect to specificpreferred embodiments thereof, many variations and modifications willimmediately become apparent to those skilled in the art. It is thereforethe intention that the appended claims be interpreted as broadly aspossible in view of the prior art to include all such variations andmodifications.

What is claimed is:
 1. A method of manufacture of footwear comprisingthe steps of: (a) providing a last with an upper thereon said lasthaving a toe region at one end thereof and a heel region at an opposingend thereof, said upper, when secured to a tread sole, fully enclosingthe wearer's foot to provide thermal insulation; (b) providing a moldinsert on the bottom of said last extending continuously from said toeregion and beneath the ball of a wearer's foot to and beneath said heelregion, and wherein said mold insert in the heel region is formed of asolid material and is of substantially greater thickness than otherportions of said mold insert; (c) providing a mold having a mold cavityfor an outer sole; (d) disposing said last and upper against said moldwith said mold insert disposed within said mold cavity; (e) forming saidtread sole having a top surface in said mold cavity, said tread solehaving a tread cavity therein in the shape of said mold insert; (f)providing an insole of premolded material in said tread cavity with atleast a portion thereof in the shape of said tread cavity extendingcontinuously from said toe region to and disposed beneath the ball of awearer's foot to and beneath said heel region including the centralportion of said heel region to provide cushioning relative to said soleand to provide support under a wearer's foot depressed against saidinsole from said toe region to said central portion of said heel region;and (g) securing said insole to said sole in said tread cavity.
 2. Amethod as set forth in claim 1 wherein steps (f) and (g) comprise thesteps of removing said mold insert from said mold cavity, disposing saidlast spaced from said tread sole and then forming said insole in thecavity formed by said removal of said mold insert and the spacing ofsaid last from said tread sole.
 3. A method as set forth in claim 1wherein said insole includes a lip portion integral therewith andextending external of said depression and over the upper surface of saidtread sole and wherein steps (f) and (g) comprise the steps of removingsaid mold insert from said mold cavity, disposing said last spaced fromsaid tread sole and then forming said insole in the cavity formed bysaid removal of said mold insert and the spacing of said last from saidtread sole.
 4. A method as set forth in claim 1 wherein said tread soleincludes one of tongues and grooves and said insole has the other oftongues and grooves, said tongues and grooves mating with each other andwherein steps (f) and (g) comprise the steps of removing said moldinsert from said mold cavity, disposing said last spaced from said treadsole and then forming said insole in the cavity formed by said removalof said mold insert and the spacing of said last from said tread sole.5. A method as set forth in claim 3 wherein said tread sole includes oneof tongues and grooves and said insole has the other of tongues andgrooves, said tongues and grooves mating with each other and whereinsteps (f) and (g) comprise the steps of removing said mold insert fromsaid mold cavity, disposing said last spaced from said tread sole andthen forming said insole in the cavity formed by said removal of saidmold insert and the spacing of said last from said tread sole.
 6. Amethod of manufacture of footwear comprising the steps of: (a) providinga last with an upper thereon having a toe region at one end thereof anda heel region at an opposing end thereof, said upper, when secured to atread sole, fully enclosing the wearer's foot to provide thermalinsulation; (b) providing a mold insert on the bottom of said lastextending continuously from said toe region to and beneath the ball of awearer's foot to and beneath said heel region, and wherein said moldinsert in the heel region is formed of a solid material and is ofsubstantially greater thickness than other portions of said mold insert;(c) providing a mold having a mold cavity for a tread sole; (d)disposing said last and upper against said mold with said mold insertdisposed within said mold cavity: (e) forming said tread sole having atop surface in said mold cavity, said tread sole having a tread cavityconforming to said mold insert; (f) forming an insole of premoldedmaterial with a first portion in the shape of said mold insert extendingcontinuously from said toe region and beneath the ball of a wearer'sfoot to and beneath said heel region including the central portion ofsaid heel region to provide cushioning relative to said sole and toprovide support under the ball of the wearer's foot and said centralportion of said heel region when depressed thereagainst; and (g)securing said insole in said tread cavity.
 7. A method of manufacturinga sole for footwear as set forth in claim 6, including the further stepof forming a tread sole substantially in the shape of said mold cavityand having a cavity corresponding in shape to the mold insert.
 8. Amethod as set forth in claim 5 wherein the mold insert is thicker at therear portion thereof than at the front portion thereof.
 9. A method asset forth in claim 7 wherein the mold insert is thicker at the rearportion thereof than at the front portion thereof.
 10. A methodaccording to claim 7 wherein said insole includes a lip portion integraltherewith and extending external of said cavity and over said treadsole.
 11. A method as set forth in claim 1 wherein said insole includesa contoured outer surface.
 12. A method as set forth in claim 6 whereinsaid insole includes a contoured outer surface.
 13. Footwear comprising:(a) a tread sole having a top surface and having a toe region at one endthereof and a heel region at an opposing end thereof and an uppersecured to said tread sole which, in conjunction with said tread sole,fully encloses the wearer's foot to provide thermal insulation; (b) saidtread sole including a cavity therein extending continuously from saidtoe region and beneath the ball of a wearer's foot to and beneath saidheel region and beneath a wearer's heel, and wherein said cavity in theheel region is of substantially greater thickness than other portions ofsaid cavity; (c) an insole with a first portion in the shape of saidcavity extending continuously from said toe region and beneath the ballof a wearer's foot to and beneath said heel region and beneath awearer's heel to provide support under a wearer's heel depressed againstsaid heel region, said first portion of said insole disposed over saidtread sole in said depression; (d) wherein said tread sole and saidinsole are formed of materials having different physical properties; (e)wherein said insole is adhesively secured to said tread sole; and (f)wherein the insole is thicker at the rear portion thereof than at thefront portion thereof.
 14. Footwear comprising: (a) a tread sole havinga top surface and having a toe region at one end thereof and a heelregion at an opposing end thereof and an upper secured to said treadsole which, in conjunction with said tread sole, fully encloses thewearer's foot to provide thermal insulation; (b) said tread soleincluding a cavity therein extending continuously from said toe regionand beneath the ball of a wearer's foot to and beneath said heel regionand beneath a wearer's heel, and wherein said cavity in the heel regionis of substantially greater thickness than other portions of saidcavity; (c) an insole with a first portion in the shape of said cavityextending continuously from said toe region and beneath the ball of awearer's foot to and beneath said heel region and beneath a wearer'sheel to provide support under a wearer's heel depressed against saidheel region, said first portion of said insole disposed over said treadsole in said depression; and (d) wherein said insole includes a lipportion integral therewith and extending external of said cavity andover said tread sole.
 15. Footwear comprising: (a) a tread sole having atop surface and having a toe region at one end thereof and a heel regionat an opposing end thereof and an upper secured to said tread solewhich, in conjunction with said tread sole, fully encloses the wearer'sfoot to provide thermal insulation; (b) said tread sole including acavity therein extending continuously from said toe region and beneaththe ball of a wearer's foot to and beneath said heel region and beneatha wearer's heel, and wherein said cavity in the heel region is ofsubstantially greater thickness than other portions of said cavity; (c)an insole with a first portion in the shape of said cavity extendingcontinuously from said toe region and beneath the ball of a wearer'sfoot to and beneath said heel region and beneath a wearer's heel toprovide support under a wearer's heel depressed against said heelregion, said first portion of said insole disposed over said tread solein said depression; and (d) wherein said insole includes a contouredouter surface.
 16. The method of claim 3 wherein said lip is disposedover the entire surface of said tread sole exterior to said cavity andwithin said upper.
 17. The footware of claim 10 wherein said lip isdisposed over the entire surface of said tread sole exterior to saidcavity and within said upper.
 18. The footware of claim 14 wherein saidlip is disposed over the entire surface of said sole exterior to saidcavity and within said upper.
 19. A method of manufacture of footwearcomprising the steps of: (a) providing a last with an upper thereon saidlast having a toe region at one end thereof and a heel region at anopposing end thereof; (b) providing a mold insert on the bottom of saidlast extending continuously from said toe region and beneath the ball ofa wearer's foot to and beneath said heel region and wherein said moldinsert in the heel region is formed of a solid material and is ofsubstantially greater thickness than other portions of said mold insert;(c) providing a mold having a mold cavity for an outer sole; (d)disposing said last and upper against said mold with said mold insertdisposed within said mold cavity; (e) forming a sole in said mold cavityhaving a cavity therein in the shape of said mold insert; (f) providingan insole of premolded material in said cavity with at least a portionthereof in the shape of said cavity extending continuously from said toeregion of and beneath the ball of a wearer's foot to and beneath saidheel region including the central portion of said heel region to providecushioning relative to said sole and to provide support under a wearer'sfoot depressed against said insole from said toe region to said centralportion of said heel region; and (g) securing said insole to said solein said cavity.
 20. A method of manufacture of footwear comprising thesteps of: (a) providing a last with an upper thereon having a toe regionat one end thereof and a heel region at an opposing end thereof; (b)providing a mold insert on the bottom of said last extendingcontinuously from said toe region and beneath the ball of a wearer'sfoot to and beneath said heel region, and wherein said mold insert inthe heel region is formed of a solid material and is of substantiallygreater thickness than other portions of said mold insert; (c) providinga mold having a mold cavity for forming a tread sole; (d) disposing saidlast and upper against said mold with said mold insert disposed withinsaid mold cavity; (e) molding said tread sole; (f) forming an insole ofpremolded material with a first portion in the shape of said mold insertextending continuously from said toe region and beneath the ball of awearer's foot to and beneath said heel region including the centralportion of said heel region to provide cushioning relative to said soleand to provide support under the ball of the wearer's foot and saidcentral portion of said heel region when depressed thereagainst; and (g)securing said first portion of said insole in said tread sole.
 21. Amethod of manufacturing a sole for footwear as set forth in claim 20,including the further step of forming a tread sole substantially in theshape of said mold cavity and having a cavity corresponding in shape tothe mold insert.
 22. A method as set forth in claim 20 wherein the moldinsert is thicker at the rear portion thereof than at the front portion.23. Footwear comprising: (a) a tread sole having a toe region at one endthereof and a heel region at an opposing end thereof and an uppersecured to said tread sole; (b) said tread sole including a cavitytherein extending continuously from said toe region and beneath the ballof a wearer's foot to and beneath said heel region and beneath awearer's heel and wherein said cavity in the heel region is ofsubstantially greater thickness than other portions of said cavity; (c)an insole with a first portion in the shape of said cavity extendingcontinuously from said toe region and beneath the ball of a wearer'sfoot to and beneath said heel region and beneath a wearer's heel toprovide support under a wearer's heel depressed against said heelregion, said first portion of said insole disposed over said tread solein said depression; (d) wherein said tread sole and said insole areformed of materials having different physical properties; (e) whereinsaid insole is adhesively secured to said tread sole; and (f) whereinthe mold insert is thicker at the rear portion thereof than at the frontportion thereof.
 24. A method as set forth in claim 21 wherein the moldinsert is thicker at the rear portion thereof than at the front portionthereof.
 25. A method according to claim 20 wherein said insole includesa lip portion integral therewith and extending over said tread sole. 26.A method as set forth in claim 19 wherein said insole includes acontoured outer surface.
 27. A method as set forth in claim 20 whereinsaid insole includes a contoured outer surface.
 28. A method ofmanufacture of footwear comprising the steps of: (a) providing a lastwith an upper thereon having a toe region at one end thereof and a heelregion at an opposing end thereof; (b) providing a mold insert on thebottom of said last extending continuously from said toe region andbeneath the ball of a wearer's foot to and beneath said heel region, andwherein said mold insert in the heel region is formed of a solidmaterial and is of substantially greater thickness than other portionsof said mold insert; (c) providing a mold having a mold cavity for atread sole; (d) disposing said last and upper against said mold withsaid mold insert disposed within said mold cavity; (e) forming a treadsole; (f) forming an insole of premolded material with a portion in theshape of said mold insert extending continuously from said toe regionand beneath the ball of a wearer's foot to and beneath said heel regionincluding the central portion of said heel region to provide cushioningrelative to said sole and to provide support under the ball of thewearer's foot and said central portion of said heel region whendepressed thereagainst; and (g) securing said portion of said insole insaid tread sole.
 29. Footwear comprising: (a) a tread sole having a toeregion at one end thereof and a heel region at an opposing end thereofand an upper secured to said tread sole; (b) said tread sole including acavity therein extending continuously from said toe region and beneaththe ball of a wearer's foot to and beneath said heel region and beneatha wearer's heel, and wherein said cavity in the heel region is ofsubstantially greater thickness than other portions of said cavity; (c)an insole with a portion in the shape of said cavity extendingcontinuously from said toe region and beneath the ball of a wearer'sfoot to and beneath said heel region and beneath a wearer's heel toprovide support under a wearer's heel depressed against said heelregion, said portion of said insole disposed over said tread sole insaid cavity; (d) wherein said tread sole and said insole are formed ofmaterials having different physical properties; (e) wherein said insoleis adhesively secured to said tread sole; and (f) wherein the insole isthicker at the heel region than at the other portions of the insole. 30.Footwear comprising: (a) a tread sole having a toe region at one endthereof and a heel region at an opposing end thereof and an uppersecured to said tread sole; (b) said tread sole including a cavitytherein extending continuously from said toe region and beneath the ballof a wearer's foot to and beneath said heel region and beneath awearer's heel, and wherein said cavity in the heel region is ofsubstantially greater thickness than other portions of said cavity; and(c) an insole with a portion in the shape of said cavity extendingcontinuously from said toe region and beneath the ball of a wearer'sfoot to and beneath said heel region and beneath a wearer's heel toprovide support under a wearer's heel depressed against said heelregion, said portion of said insole disposed over said tread sole insaid cavity.